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Project Thunderbird

lewis77

Active Member
Here's the project report for the ph1, started one now I've found a name for it!

This page is a list of work to be done colour coded by priority, and a running total of all costs incurred on the car.

Tasks to do:

Urgent:
Fix coolant leak (Head Gasket?)



Important:
Fix tachometer
Recon or replace gearbox


To do:
Extreme wash and polish, bringing up faded wings
Replace spark plug connectors
Replace cracked O/S wing mirror
Treat all rust


Would like:
Full exterior respray
Full stainless exhaust system


(Completed)
Full service
Replace nearly worn brake disks
Replace fuel pump
Fix badly leaking fuel pump
Identify and fix oil pressure problem
Investigate gearbox
Fix overheating problem
Fix O/S window
Fix O/S Lock
Fix N/S window
Replace all exhaust mounts
Change faded rear light lenses
Investigate mpg calc



Totals:
£750 - Cost of car
£104.5 - 6 Months tax
£7.68 - 4 Exhaust mounts
£30.90 - Windscreen repair
£20.49 - Spark plugs
£5.98 - Battery terminals
£123.10 - 2x Drivshafts
£36.76 - Diff oil 75W-80
£14.39 - Antifreeze
£19.99 - Mobil 10w-40
£2.63 - Oil filter
£8.81 - Fuel filter
£2.48 - Sump plug
£10.99 - KSeal coolant sealant
£81.08 - Clear fog lights
£15 - Rear quarter windows


Total - £1234.78

[BREAK=Meet the Rocket]

So to start at the beginning

Basically started out at 2am to pick up the ph1 Hatch from Spryboy, down in Devon. It was a long way down from me in Northants but a fairly easy drive.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_020101.webp

Due to insurance and whatnot, or rather not being able to arrange it in time, Gbuk offered to help drive the car back once we got down there. A million thanks to him, absolute legend!

First order of the day: Food. Driver re-fuelling if you will ;). The McDonalds lady was a little funny! (Gbuk - I met her again 24 hours later on the Monday morning! :D)

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_0439.webp

Then comes the trusty Diesel's breakfast, the first of three meals within 24 hours! :eek:

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_0635.webp

Notice the added 'boost' power!

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_063501.webp


Eventually we arrived in Devon, and found the car. 6 hours in total. Lurking in an alleyway behind some garages, like a little gem in a haystack.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_0820.webp

Not a bad looking specimen of a ph1 19! Couple of niggles and surprises; Battery was flat (brought my own though!), Rev counter didn't work, Whiney fuel pump, and slight whine from gearbox. Nothing too major, and I received a box of bits with it anyway.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_0822.webp

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_0827.webp

A nice healthy 12 gallons of Shell V-Power to fill up, according to the trip comp.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_0830.webp

Not too bad, nice and cheap this end of the country, seems to get more expensive the further NE you go!

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_0840.webp

Nice interior (doesn't matter though, since I wasn't sitting in it :p). I plan to play swapsies with the white 19 though for leather.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_084001.webp

However, this I did like! When Gbuk told me on the way down that it wasn't as standard as I had thought, and explained the mods I was amazed! I had no idea there was a beast of a 2.0l megane under the hood! (Pays to do your research, however I like nice surprises!)

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_0856.webp
A familiar sight for the next 6 hours home...

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_0900.webp
i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_1024.webp
i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_102401.webp
i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_1120.webp
Two VERY different ends of the 19 spectrum!

However this is where the problem arose...
Lack of power on acceleration, and when we pulled up, popping and backfiring like a biatch, plus a lovely trail of petrol fumes.
Sounded like a cylinder wasn't firing. So off with the bloody hot spark cap, and to the plugs:

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_1135.webp

No.4 cylinder was brimmed with water! Bloody bonnet vent betraying the plugs again! Once this was cleaned out and the others were checked it ran sooo smoothly and quietly, and apparently the gearbox whine stopped :?.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_1206.webp
Photo Op's
i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_1207.webp

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_1311.webp
i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_1312.webp
The final straight down the A14, where it 'happened' to hit 120, while still pulling like a chubby chaser at a fat farm.


i154.photobucket.com_albums_s264_deathstar777_J298GOT_P04_10_09_1637.webp
Finally home...
I cannot wait until the time comes when I get to sit behind the wheel!


That's the effort of picking the Beast up! 1000 miles, 12 Hours, And apprx. £275 in travel expenses, and I couldn't be happier! Next to fully wash, inspect and get to know the car.

[BREAK=Work Begins]

Well I haven't seen the car for 3 weeks due to work :(

But I'm back now and the first sting was finally getting it insured, several places wouldn't quote (hardly surprising). And eventually, when I did find a half reasonable price... well... I could rant forever about stupid insurance...

Took it out for a little spin after that. All I can say is I've never driven anything with more than about 70 horses, and after the diesel.. well I now know why everyone likes the valvers so much :mrgreen:
I am officially a self diagnosed fanatic now!

Anyway, didn't really do much Sunday apart from drive :D... Until I ran out of fuel :oops:

i154.photobucket.com_albums_s264_deathstar777_J298GOT_BrokenDown.webp

Yes it died on the side of the A14 :(. Ok I know that sounds like a daft thing to do ("who doesn't know when to put fuel in their car" etc), But I have my excuses ready! The trip comp doesn't work so when it died I 'apparently' had a gallon left and 84 miles to go :?. And I wanted the tank as empty as possible for when I did the fuel pump on Monday.
Nevertheless I pushed this with one hand about 500 odd yards, I did notice one good thing - It's light as f**k! :D

Ok enough of that, the mechanics.
All the exhaust mounts were either corroded or missing so picked up 4 more.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_BackboxBracket.webp
i154.photobucket.com_albums_s264_deathstar777_J298GOT_CenterBracket2.webp
i154.photobucket.com_albums_s264_deathstar777_J298GOT_CenterBracket.webp
Cable ties! Again!? I mean come on!

i154.photobucket.com_albums_s264_deathstar777_J298GOT_ExhaustMounts.webp
New mounts and old.

The mounts were a pain to get in as the megane downpipe pulls the whole exhaust slightly forward, probably why they've worn. Still it has 3 boxes on and a cat, all but the back box will be going as soon as I can get the straight pipe off the white 19.

Next was the turn of the fuel pump. I had pulled the one from the white 19 off the week before as a replacement, so just needed to drop the tank and swap them over.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_FuelTank.webp

Wasn't too hard, the 18 year old bolts put up a fight mind!

i154.photobucket.com_albums_s264_deathstar777_J298GOT_FuelPump.webp

Pumps were swapped over with the old whiney one being chucked. I had totally forgotten about the pressure the out line is under nearly had a massive accident! :eek:
But clamped the hose and everything is a case of unplug/re-plug.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_TankBack.webp

All back up and running...

However, yesterday night the pump started whining again! Just like the last, and apparently when it's booted, the pump just throws fuel all over the top of the tank. The guy following me said about a litre came out when I overtook someone :eek:. I don't think the replacement is seated correctly, I might put a rubber washer in, and check the connections tomorrow, since a new pump is £140!

So I didn't really fix anything yet, Just broke it more :(

[BREAK=Windows and Locks]

Well a bit of work today, nothing major. Still not got round to dropping the fuel tank again :roll:

Thought I'd fix the windows and the O/S lock, none are working very well (N/S isn't working at all).

First job - Door card off
i154.photobucket.com_albums_s264_deathstar777_J298GOT_P28_10_09_1230.webp

It's weird having all the electrics to unplug!

I cleaned and oiled up the window regulator and tested it seemed fine.
All went back in until I realised that one of the threads was stripped, hence why it wasn't going up very quickly, the up bar was wonky.

So I pulled the one out of the spare door I have in my garage.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P28_10_09_1221.webp

Same drills again, all clean, in it goes. It's still a bit slow, but I think it might be the worn rubbers holding it back. Still I have a full new set on the white 19
:mrgreen:

Door locks next, as suspected it was a knackered solenoid just not locking it 100% of the time.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P28_10_09_1303.webp

Swapped them over, wd40'd the lock, all better :)
I fixed something for once!

Then on a drive to and from MK center yesterday, I 'had' to go fast (;)) to keep engine temps down, something wrong there!

Firstly fan wasn't cutting in, and my dash lights were flashing like a disco! Temp light, Oil check light, and the pressure guage back light :?, were all going.
So fan out, quick test

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P28_10_09_1627.webp

Well it works, but I know why it won't cut in:

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P28_10_09_1629.webp

Obviously a 19 radiator and fan, with a Megane engine loom spliced in, one of the connections came loose, same as on the diesel a couple of months ago :)

Terminal block in, quick blast, fast idle, fan keeps the temp lovely. Job done (y)

Then I swapped the light clusters over with the spares that came with it, since one was orange and one was pink!

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P28_10_09_1557.webp
New one fitted

Then a new bulb to give me reverse lights on both sides again.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P28_10_09_1556.webp

All I've done for now.
Mind you I noticed this early yesterday

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P28_10_09_1121.webp

I'm thinking new door? Answers on a postcard please

[BREAK=Driveshafts and Other Bits]

Well It's been a fairly long time since I updated this. Mainly due to lack of funds and time what with winter cutting out all of my after work light.

To bring you back up to speed some recent developments, firstly I've updated the Preface page to show recent changes. So working through the completed list:

Fuel pump has all been sorted now, turns out I didn't replace the rubber seal when I put it back in and there was a small gap between it and the tank :oops: sorted now though, and no whining!
Oil pressure problem, is most definitely the gauge as it will behave differently under all different conditions so not too worried as it usually works fine, could be compatibility issues with the engine again.
Gearbox doesn't seem to be too much of an issue, sounds like the bearing is going in 5th, since it makes the quietest whine at 70, will look at a replacement soon though, since the diesels just went big style!
Obviously the overheating problem was the fan not connected so since that was sorted I've had no further issues.
O/S window and lock are all working fine now, as is the N/S window. Just leant against it while moving it down and it came unstuck!
And the mpg calculator is completely down to the incompatibility with the Megane ECU, so distant future will see an F7P Top/F7R Bottom conversion to get the ECU and wiring loom back. Should sort it easier than a Megane dash replacement.

So that's the gen so far. Now what I've spent the last 2 weeks doing!

Little things like spark plugs were changed and the oil will be done this weekend with some decent stuff, also took the opportunity to buy some battery terminals as well

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P06_02_10_1045.webp

I then sourced and bought a set of drive shafts since the outer CV joint on the N/S was rusty and the play was ridiculous.
Now considering I had to do this in a car park in the evening in the dark, cold and stupid Welsh weather, I don't think it went too badly!

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P03_02_10_1552.webp

Stripped it all down and then spent ages trying to make a roll pin for the O/S shaft, that didn't fit in the end :(
So bought 25 off eBay (stupid minimum orders!), Eventually it went back together, but upon filling it up, at around 700ml, it started pouring out from the flange at the N/S inner CV joint. I instantly thought this was because I'd bent the metal ring inside the new boot. But it annoyed me so I came back to it another night.
After stripping it all down and changing the boot for the old one I only then realised my stupid mistake. The retaining flange has a lip to push the boot home... that was the wrong way round :eek:
So feeling like a prat I put it all back together and filled up the box to my amazement I'd finally fixed something properly!

How it looks now:

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P06_02_10_104502.webp

Thought it was ropey but it holds well!


Apart from that I discovered I need new brakes and pads. Desperately!

om_albums_s264_deathstar777_J298GOT_P03_02_10_1554.webp

The disks used to be grooved but only have faint lines now! :?
And the pads aren't much better.
Quick phone call to HiSpec, and the pads are easy enough, but apparently the dimensions of the disk are nothing they make! 285mm and mine are 292mm. So not really sure where they were got from before but I'm stuck unless I find a source quickly. Ideas?

It's also using a lot of coolant, I mean it'll drink between the max and min lines during 150 miles at 70 :eek:.
I firmly believe this is connected to the constant white smoke out of the exhaust, which increases with revs! Yay, another car, another head gasket! Stupid engine was rebuilt apparently! :?
Still as it's on a driving holiday next week for 3 days, I have a temporary sealant to add to the coolant until I can properly sort it.

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P28_12_09_141401.webp


And a quick question - Any body know why on earth I have a second mid section with only one pipe??

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P30_10_09_1504.webp

I'm guessing extra dampening but its a silly design!


So until the next time I tackle this (hopefully Saturday)...

[BREAK=Summer Starts Work Again]

Well Summer's back and the weather is mechanics weather (y)!

I'll update with the follow up from last time followed by some new parts!

i154.photobucket.com_albums_s264_deathstar777_J298GOT_P13_02_10_141901.webp
Basically everything that went in with the major service.

I changed the radiator over for one that was less rotten.

Before:
i154.photobucket.com_albums_s264_deathstar777_J298GOT_P13_02_10_145901.webp

After:
i154.photobucket.com_albums_s264_deathstar777_J298GOT_P13_02_10_145902.webp

New one on the left:
i154.photobucket.com_albums_s264_deathstar777_J298GOT_P13_02_10_1459.webp

Also changed the Aux water pump over for one I had refurbed before, and changed the fan for a better looking one.

So basically new oil went in, Mobil 10W-40 and new filter at 81000 miles, new sump plug as well. It's a mm smaller than my plug key though which is annoying :(

Also changed the fuel filter, badly needed after all my fuel issues! :roll:

Next step was to change and flush out the coolant system, as well as put in my K-Seal to try and sort the leak/s that are causing me to lose coolant :?

Flushing the system:
i154.photobucket.com_albums_s264_deathstar777_J298GOT_P13_02_10_1419.webp

After this it all improved for about a week, now I'm still losing water and getting the same smoke from the exhaust but it stops dropping when it gets to a certain level just below the minimum mark :?.

With my MOT coming up soon I needed to change the front brakes, which were dangerously low, and the fog lights as the bulbs were gone and soldered in :roll:

So ordered some clear ones from K-Tec for the Mk1 Clio, which are the same apparently.

And fitted them:
i154.photobucket.com_albums_s264_deathstar777_J298GOT_FoglightFitting.webp

Needed some modification as I broke the standard mounting clips but they fit well now. Unfortunately the connectors are for a ph2 19 (or Mk1 Clio) and don't fit the rubber connectors of the ph1 19.

So a little soldering and heat shrink later and I have my hybrid waterproof connectors:
i154.photobucket.com_albums_s264_deathstar777_J298GOT_FoglightCables.webp


Brakes were a little more tricky. After finally sorting out where to get my replacements from HiSpec they were delivered.

Old and new:
i154.photobucket.com_albums_s264_deathstar777_J298GOT_BrakeDisk.webp

They're the two piece variety meaning I had to change the centre bell over.

And my EBC Greenstuff Pads to fit my callipers:
i154.photobucket.com_albums_s264_deathstar777_J298GOT_BrakePads.webp


I had to retract the pistons in the callipers as much as physically possible because the space was mm perfect with new disks and pads.
i154.photobucket.com_albums_s264_deathstar777_J298GOT_BrakePistonReturn.webp


After they were all fitted:
i154.photobucket.com_albums_s264_deathstar777_J298GOT_BrakesFitted.webp

This was a pain as the brakes were fully on for the first couple of miles until the surface coat bedded in, callipers weren't really designed for these disks!
Once sorted though this setup is astronomical!! They really do stop!
However one of them is slightly out of balance, as it vibrates a small amount at about 60-70 :(
Might try to machine some off if I ever get the chance

Next update is on the MOT from the end of March, I know I'm behind! Oh... and the test was a biggy :roll:
 
Last edited by a moderator:
Thunderbirds are go lewis.

love this already, nicely laid out and all. best of luck with it.
 
Woah you only paid 750 for it, i offered 750 and he said no! ya got a gooden there, but dude you might find you will have to fit the entire meggy dash to get the clocks/mpg to work, pm mickpm

Prab
 
Hey dude just noticed, you want original turbines, they won't fit over the big brakes spryboy fitted

Prab
 
new door, welding or blissful ignorance my friend... loving watching this progress lewis, i for one know she's in the right hands with you, keep up the adventure
 
new door, welding or blissful ignorance my friend... loving watching this progress lewis, i for one know she's in the right hands with you, keep up the adventure

Thank you, good to see some faith in the inexperienced :D

welded should be fine, dont think you need go as far as a new door

Oh thank god, really don't like un-doing the door hinges, I'll get it priced up sometime then.
 
The over heating issue sounds like the one in one of my cabbys, overheats quite quickly but in high revvs she cools right back down again, turns out mine is an extremely weak water pump, if i leave her sitting running in the garden she'll crep right up, fan kicks in but cant work to keep it cool enough but if i rev her hard even just for a few seconds the temp goes right back down to normal again
 
out of balance under braking? are you sure you didnt trap rust behind the disk when putting the new disks on?

Possibly, I did clean them before they went on though. May have to take them off again for a thorough once over though. I know they look out of balance on the edge with the wheels up and in 1st.
 
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